Automatic overhead gantry for narrow slit rolls handling

ABSTRACT

A system for automatic handling and sorting of narrow-slit rolls. Wherein the system is also capable of preventing toppling of the narrow-slit rolls.

CROSS-REFERENCE

The present patent application is based upon and claims the benefit of provisional patent No. 63/153,655, filed Feb. 25, 2021.

BACKGROUND OF THE INVENTION

When manufacturing paper products, large rolls of tissue paper are provided for processing into various products such as bath tissue, paper towels, air dried, and crepe air dried materials such as napkins. The rolls of tissue are provided on cores and may weigh up to 8,000 pounds. The tissue is rolled on the core and may be 90 inches in diameter. Paper manufacturers receive these rolls and unwind them to process the tissue paper into the various products being manufactured. Certain paper applications require strips of tissue paper narrower than the large rolls, known as narrow-slit rolls. These narrow-slit rolls can vary in thickness depending on the desired application. The narrow-slit rolls are cut from the large roll to a desired thickness. The narrow-slit rolls, given their narrow width are not capable of standing unassisted without risk of falling over. Despite being narrow, the narrow-slit rolls can still weigh hundreds to thousands of pounds depending on the width. This heaviness coupled with the unstable nature of narrow slit rolls outs users at high risk for injury. There is a need in the industry to safely handle and move narrow slit rolls.

SUMMARY OF THE INVENTION

The system is designed to automatically handle and sort narrow-slit rolls.

The system receives the rolls from the winder controlling the full roll set with combination of pneumatic roll cushion and powered roll stabilizer arms. Once contained on the conveyor, the system uses a combination of a roll pressure plate and conveyor drive to index the slit rolls forward to pick up position. The correct number of roll or rolls to pick up is determined automatically by the data transmitted from the customer winder and order. Using either an ID probe or three-point cradle on outside diameter, the roll or rolls are safely picked up automatically via automatic overhead gantry. The automatic gantry using servo controls moves within the XYZ axis to pick and place the roll or rolls according to SKU order requirements. The automatic gantry lifts a roll horizontally and maintains roll in this orientation. The invention can be customized to handle any width of narrow-slit from as small as ¼″ up to and including a full roll. In the present embodiment the invention is designed for a user that desires to handle and sort narrow slits roll 3″ wide up to 20″ wide. However, it should be understood that the invention can be tailored handle any size narrow-slit, up to and including a full roll. The rolls can be placed individually on roll queue stands or directly onto an upender or packaging machine then feeding an outfeed transport system to warehouse.

The system movements are all of electric controls and the hold down is pneumatic to accommodate varying diameters and amounts of pressure required. The footprint of the system is contained within a small overhead self-supporting steel structure. All operations are contained safely inside this structure.

The overhead gantry using electric vertical lift and two-point cradle engages the roll from the bottom and a pneumatic vertical hold down is engaged to contain the load while the system pressure plate is repositioned for the next roll. The gantry raises vertically simultaneously moving to the destination for roll set down via CIP motion controls. Roll set down occurs by lowering the load to roll stand, upender infeed or packaging station using the same controls in reverse. This pick and place and index sequence is repeated until the full roll set is empty/complete and ready for next roll set to be discharged from winder. The controls system tracks the rolls data individually for building SKUs or finished customer orders. This also allows the system to be sorting rolls into orders while the next set is winding.

IN THE DRAWINGS

FIG. 1 is a perspective view of a narrow-slit handler.

FIG. 2 is a perspective view of a narrow-slit handler.

FIG. 3 is a side view of a narrow-slit handler with framing removed.

FIG. 4 is a side view of a narrow-slit handler.

FIG. 5 is a side view of a cushioner, hold down and upender r of the narrow-slit handler.

FIG. 6 is a perspective view of a narrow-slit handler.

FIG. 7 is a perspective view of a narrow-slit handler.

FIG. 8 is a perspective view of a narrow-slit handler.

FIG. 9 is a side view of a narrow-slit handler.

FIG. 10 is a perspective view of a narrow-slit handler.

FIG. 11 is a perspective view of a narrow-slit handler without a gantry.

FIG. 12 is a side view of a cushioner and hold-down.

FIG. 13 is a perspective view of a narrow-slit handler.

FIG. 14 is a perspective view of a narrow-slit handler without a gantry.

FIG. 15 is a perspective view of a narrow-slit handler.

FIG. 16 is a top view of a narrow-slit handler.

FIG. 17 is a front view of a narrow-slit handler.

FIG. 18 is a perspective view of a cushioner with stabilizer arms.

FIG. 19 is a front view of a hold-down.

FIG. 20 is a top view of a hold-down.

FIG. 21 is a side view of a hold-down.

FIG. 22 is a top view of a cushioner with stabilizer arms.

FIG. 23 is a front view of a cushioner with stabilizer arms.

FIG. 24 is a perspective view of a hold-down.

FIG. 25 is a perspective view of a kicker.

FIG. 26 is a perspective view of a kicker.

FIG. 27 is a back view of an overhead gantry.

FIG. 28 is a perspective view of an overhead gantry.

FIG. 29 is a side view of an overhead gantry.

FIG. 30 is a top view of an overhead gantry.

FIG. 31 is a perspective view of a narrow-slit storage unit.

FIG. 32 is an exploded view of a cushioner with stabilizer arms.

FIG. 33 is an exploded view of a hold-down.

FIG. 34 is an exploded view of an overhead gantry with support framing removed.

FIG. 35 is a perspective view of an overhead gantry with support framing removed.

FIG. 36 is an exploded view of a gantry traversing frame.

FIG. 37 is an exploded view of an overhead gantry with framing removed.

DETAILED DESCRIPTION

Referring now to FIGS. 1-17, a narrow-slit handler 1 is shown. The narrow-slit handler 1 comprises an overhead gantry 5, a cushioner 10 with stabilizer arms 11, hold-down 15, conveyors 25, kickers 20, narrow-slit storage 30, and upender 35.

A roll 3, which has been previously cut into slits of desired widths (narrow-slits 2), enters the narrow-slit handler at ramp 45. The cushioner 10 extends to meet roll 3 with a cushion 12 and at least two stabilizer arms 11. The cushioner 10, using the cushion 12 and stabilizer arms 1, guides roll 3 down ramp 45 and onto conveyor 25. Hold-down 15 centers itself on roll 3 and lowers hold-down arms 16 to make contact with roll 3 and hold the narrow-slits in position to prevent toppling. Overhead gantry 5 positions itself to the side of roll 3, selecting the desired number of narrow-slits 2, clamping the narrow-slits 2 into place and transports the narrow-slits to at least one narrow-slit storage 30 (FIG. 31). Narrow-slit storage 30 is sloped down such that once the narrow-slits 2 are placed into the narrow-slit storage 30 they do not topple as they rest against the back of the narrow-slit storage 30. The overhead gantry 5 can organize the narrow-slits 2 by any parameter if there is more than one narrow-slit storage 30, but they are typically arranged by size.

A user requests a package of narrow-slits. This package could be all the same size narrow-slits or of varying sizes. The overhead gantry 5 then picks the desired narrow-slits and assembles the package at an upender 35. Once the package is completed, the upender 35 upends the package and it is sent on for further processing.

Alternatively, if the narrow-slit is wide enough that it will not topple on its own (or a full roll), the narrow-slit handler 1 bypasses the overhead gantry 5 by conveying the narrow-slit to a kicker 20. Kicker 20 pushes the narrow-slit onto ramp 50, the narrow-slit then rolls to a second kicker 20 which stops the narrow-slit and seats the narrow-slit onto a second conveyor 25 which transports the narrow-slit to upender 35 where it is upended, individually or as part of a package, and sent for further processing.

Referring now to FIGS. 18, 22-23, and 32, the cushioner 10 having at least two stabilizing arms 11 is shown. The cushioner 10 comprises a frame 46 in communication with an extending frame 13. The extending frame 13 having a cushion 12 and stabilizing arms 11. A stabilizing arm motor is in communication with stabilizing arms 11 and is capable of extending and retracting stabilizing arms 11. Cushion cylinders 14 are attached to frame 46 and in communication with extending frame 13, such that when acted upon the cushion cylinders 14 extend the extending frame 13 to meet a roll 3. Similarly, the cushion cylinders 14 can retract the extending frame 13.

Referring now to FIGS. 19-22, 24, and 33 the hold-down 15 is shown. The hold-down 15 comprises a frame 22, linear tracks 17, hold down rails 16, traversing motor 18, lift chain 19 and lift motor 21. The hold-down arms 16 traverse the frame 22 with linear rails 17, linear guides 24 and traversing motor 18. The hold-down rails are raised and lowered with a lift motor 21, lifting chain 19, linear rails 23 and linear guides 24.

Referring now to FIGS. 25-26 a kicker is shown. The kicker is known to those skilled in the art.

Referring now to FIGS. 27-30, and 34-37, the overhead gantry 5 is shown. The overhead gantry 5 comprises frame 40, overhead frame 43, traversing frame 42, mast 4 in connection with a gantry hold-down 6, a lifting frame 8, and a cylinder 9. The overhead gantry 5 is capable of moving along the x-y axis, as well capable of turning mast 4 360 degrees. The mast 4 traverses the overhead frame 43 with linear rails 44 and traversing motor 48 by use of traversing pulleys 36 and a traversing belt. The overhead frame traverses 43 the frame 40 with overhead traversing motor 55 and rails. The mast 4 rotates 360 degrees with rotation frame 41 and rotation motor 39. Rotation frame 41 also includes sprocket 52 and slew ring 53 which are in communication with mast 4 and allow the mast to rotate. The lifting frame 8 moves along mast 4 using linear rails 23 and linear guides 24. The gantry hold-down 6 moves in conjunction with the lifting frame 8 until acted on by cylinder 9 to clamp down on narrow-slits 2. The lifting frame is moved up and down with vertical drive 37 and drive chain 38. The lifting frame having at least two lifting probes 7 spaced apart at or near the bottom the lifting frame.

Wherein a programable logic control is programmed to control the movements of all parts of the narrow-slit handler 1 such that a user can input a desired package, the narrow-slit handler 1 will process the narrow-slits and build the desired package, without allowing the narrow-slits to topple over.

Described above is the preferred embodiment of the invention. It is understood that that one skilled in the art could employ different embodiments could employ different types of rails, motors, cylinders, etc. 

We claim:
 1. An automated apparatus for handling and sorting narrow-slits comprising, in combination: a cushioner having a cushion and at least two stabilizing arms; a hold-down with at least one hold down arm; and an overheard gantry having a lifting frame and a gantry hold-down;
 2. The apparatus of claim 1 wherein the lifting frame of the overheard gantry has at least two lifting probes.
 3. The apparatus of claim 2 further including at least one narrow-slit storage.
 4. The apparatus of claim 3 further including at least one kicker.
 5. The apparatus of claim 4 further including at least one upender.
 6. The apparatus of claim 5 further including at least one conveyor. An automated apparatus for handling and sorting narrow-slits comprising, in combination: a cushioner having a cushion and at least two stabilizing arms; a hold-down with at least one hold down arm; an overheard gantry having a lifting frame and a gantry hold-down; at least one conveyor; at least one kicker; at least one narrow-slit storage; at least one updender; and wherein the components are controlled by a programable logic controller configured to transport and sort narrow-slits.
 7. The apparatus of claim 6 wherein the programable logic controller is further configured to differentiate between narrow-slits of varying width, and sort the narrow-slits in the at least one narrow-slit storage by the width of the narrow-slit.
 8. The apparatus of claim 7 wherein the programable logic controller is further configured to allow a user to input a desired order of narrow-slits, based on the width of the narrow-slit, and the overhead gantry will assemble the narrow-slits at the upender as requested.
 9. A method of transporting and sorting narrow slits comprising, receiving a roll, having at least one narrow-slit cut into it, with a cushion and stabilizing arms; positioning the roll onto a conveyor with the cushion and stabilizing arms; holding the roll with a hold-down; clamping a desired quantity of narrow-slits from the roll using an overhead gantry; releasing the hold-down; repositioning the hold-down on the roll such that the desired quantity of narrow-slits clamped by the overhead gantry are no longer held by the hold down; determining the width of the picked narrow-slits; picking up the desired quantity of narrow-slits from the roll using an overhead gantry; and sorting the narrow-slits by width by placing the narrow-slits at a narrow-slit storage unit.
 10. The method of claim 9 further including building a package of narrow-slits based on a request from a user. 